WO2013001591A1

WO2013001591A1 - Inductor and manufacturing method therefor

Info

Publication number: WO2013001591A1
Application number: PCT/JP2011/064686
Authority: WO
Inventors: 上野　泰弘; 文夫野溝
Original assignee: トヨタ自動車株式会社
Priority date: 2011-06-27
Filing date: 2011-06-27
Publication date: 2013-01-03
Also published as: US9153372B2; US20140125440A1; EP2725591B1; JP5626466B2; EP2725591B9; EP2725591A1; CN103650077B; EP2725591A4; JPWO2013001591A1; CN103650077A

Abstract

An inductor that has the following: an inductor core comprising a plurality of core members arranged in a ring with gaps therebetween; primary insert-molded resin parts comprising a thermoplastic resin covering the outside surface of the inductor core, excluding the surfaces of the core members that face each other; coils disposed around the aforementioned gaps and the primary insert-molded resin parts on the inductor core; and secondary insert-molded resin parts comprising a thermoplastic resin insert-molded around the coils to affix said coils to the inductor core. This allows high-cycle manufacturing of inductors without a thermosetting-resin potting step in a vacuum furnace or a heat curing treatment in a heating furnace.

Description

Reactor and manufacturing method thereof

The present invention relates to a reactor and a manufacturing method thereof, and more particularly to a reactor mounted on an electric vehicle, a hybrid vehicle, and the like and a manufacturing method thereof.

Conventionally, a reactor is incorporated in a part of a power conversion circuit mounted on an electric vehicle such as a hybrid vehicle. This reactor is used, for example, in a converter that boosts DC power supplied from a battery and outputs the boosted power to a motor that is a power source.

Generally, a reactor is composed of a plurality of core members made of a magnetic material, a reactor core formed by annularly connecting these core members with a non-magnetic gap plate interposed therebetween, and a periphery of a coil mounting position of the reactor core including the gap plate. And a coil disposed on the surface. The reactor including the reactor core and the coil is mounted on the vehicle in a state of being fixed by a bolt or the like in a metal case such as an aluminum alloy.

Here, as a prior art document related to the reactor as described above, for example, Japanese Patent Laid-Open No. 2009-99793 (Patent Document 1), a reactor core including a coil is accommodated and fixed in a housing, and the housing and the reactor core are connected. And a method of manufacturing a reactor in which a silicone resin is impregnated and cured between the coil and a coil to fix the reactor in a housing.

Japanese Patent Laid-Open No. 2009-27000 (Patent Document 2) discloses that a core unit is formed by connecting a plurality of magnetic I-type cores via a gap, and a gap is formed between the ends of the two core units. A substantially annular reactor core is formed by connecting U-shaped cores having a core, a coil is formed on the outer periphery of the core unit to form a reactor, and a resin is placed between the reactor and the housing in a posture in which the reactor is accommodated in the housing. A reactor device in which a mold body is formed is disclosed. In this reactor device, it is described that the resin mold body is formed at the coil forming portion of the reactor, and the resin mold body is not formed between the U-shaped core and the housing.

JP 2009-99793 A JP 2009-27000 A

In the reactors of Patent Documents 1 and 2, an annular reactor core with a coil assembled therein is accommodated in a housing, and a silicone resin, which is a thermosetting resin, is poured into a gap between the housing, the reactor core and the coil, and filled. The potting process is performed, and the silicone resin is cured by performing a heat treatment, so that the coil is fixed to the reactor core, and the heat dissipation from the coil to the housing is interposed with a highly thermally conductive silicone resin. It is secured by letting.

In the potting process as described above, if bubbles are included in the poured silicone resin, a heat insulating layer is formed and heat dissipation from the coil to the housing is hindered. Therefore, it is necessary to pot the silicone resin in a vacuumed state in a vacuum furnace so as not to contain such bubbles.

In addition, in order to sufficiently cure the potted silicone resin, it is necessary to transfer it into a heating furnace and perform a heat treatment of, for example, about 2 to 3 hours, which has been a factor in prolonging the reactor manufacturing cycle time. .

The objective of this invention provides the reactor which abolishes the potting process of the thermosetting resin in a vacuum furnace, and the heat-hardening process in a heating furnace, and enables manufacture in a high cycle, and its manufacturing method There is.

A reactor according to an aspect of the present invention covers a reactor core in which a plurality of core members are annularly connected via a gap portion, and covers an outer peripheral surface of the reactor core except at least a facing surface between the core members. A primary insert molding resin portion made of a thermoplastic resin provided; a coil disposed around the primary insert molding resin portion of the gap portion and the reactor core; and the coil formed by insert molding around the coil. And a secondary insert molding resin part made of a thermoplastic resin that fixes the resin to the reactor core.

The reactor which concerns on this invention WHEREIN: The said secondary insert molding resin part contains the coil exposure part which exposes the said coil in the part facing the reactor installation member in which the said reactor is installed, and the said coil exposure part is via a thermal radiation material. And may be attached in contact with the reactor installation member.

Further, in the reactor according to the present invention, the secondary insert molding resin portion may be formed of a resin material having higher thermal conductivity than the primary insert molding resin portion.

Furthermore, in the reactor according to the present invention, the primary insert molding resin portion or the secondary insert molding resin portion may be integrally formed with an attachment portion for bolting the reactor to a reactor installation member.

According to another aspect of the present invention, there is provided a method for manufacturing a reactor comprising: a reactor core in which a plurality of core members are annularly connected via a gap portion; and a coil provided around the reactor core including the gap portion. A reactor manufacturing method comprising: preparing the plurality of core members and the coil; covering at least an outer peripheral surface of the core member excluding an opposing surface of the core members; and a primary insert molding resin portion made of a thermoplastic resin And surrounding the coil disposed around the gap portion and the primary insert molding resin portion of the reactor core, with the plurality of core members being inserted into the coil in a ring shape through a gap portion. Forming a secondary insert molding resin portion made of thermoplastic resin on the coil and fixing the coil to the reactor core. Including the.

In the manufacturing method of the reactor according to the present invention, when forming the secondary insert molding resin portion, forming a coil exposure portion that exposes the coil at a portion facing a reactor installation member where the reactor is installed, You may assemble | attach in the state which the coil exposure part contacted the said reactor installation member via the heat radiating material.

Further, in the reactor manufacturing method according to the present invention, the secondary insert molding resin portion may be formed of a resin material having higher thermal conductivity than the primary insert molding resin portion.

Furthermore, in the method for manufacturing a reactor according to the present invention, when the primary insert molding resin portion or the secondary insert molding resin portion is formed, an attachment portion for bolting the reactor to the reactor installation member is integrally formed. Also good.

According to the reactor according to the present invention and the manufacturing method thereof, the coil disposed around the gap portion and the primary insert molding resin portion in the reactor core is fixed by the secondary insert molding resin portion made of thermoplastic resin. Therefore, the potting process of the thermosetting resin in the vacuum furnace and the heat curing treatment in the heating furnace are abolished, and the reactor can be manufactured in a high cycle.

It is a perspective view which shows the core member of the reactor core which comprises the reactor which is one embodiment of this invention. It is a perspective view which shows the state which formed the primary insert molding resin part which consists of thermoplastic resins in the core member of FIG. It is a disassembled perspective view which shows a mode that the two core members shown in FIG. 2, a coil, and two gap plates are assembled | attached. FIG. 4 is a perspective view showing a reactor core and a coil in a state in which a core member, a coil, and a gap plate shown in FIG. 3 are assembled. It is a perspective view which shows the state which formed the secondary insert molding resin part in the reactor core and coil shown in FIG. 4, and fixed the coil. It is a perspective view which shows the coil exposure part formed in the lower part of the secondary insert molding resin part. It is a disassembled perspective view which shows a mode that the reactor to which the coil was fixed is bolt-fixed on a metal case bottom plate via a heat radiating material. It is a longitudinal cross-sectional view of the reactor fixed on the metal case bottom plate. It is a perspective view similar to FIG. 6 which shows a mode that the secondary insert molding resin part protrudes in the coil exposure part, and the burr | flash part is formed. It is the longitudinal cross-sectional view similar to FIG. 8 which shows the state which covered the secondary insert molding resin part without exposing a coil, and was attached directly on the metal case bottom plate.

Hereinafter, embodiments (hereinafter referred to as embodiments) according to the present invention will be described in detail with reference to the accompanying drawings. In this description, specific shapes, materials, numerical values, directions, and the like are examples for facilitating the understanding of the present invention, and can be appropriately changed according to the application, purpose, specification, and the like. In addition, when a plurality of embodiments and modifications are included in the following, it is assumed from the beginning that these characteristic portions are used in appropriate combinations.

FIG. 1 is a perspective view showing a core member 14 of a reactor core 12 constituting a reactor 10 according to an embodiment of the present invention. The reactor core 12 in this embodiment is composed of two core members 14 having the same shape.

The core member 14 is formed in a substantially U shape in a plan view, and has a substantially arc shape in a plan view connecting the first leg portion 16 and the second leg portion 18 projecting parallel to each other and the

leg portions

16 and 18. Connection portion 20. The core member 14 is preferably constituted by a powder magnetic core formed by pressure-molding resin-coated magnetic powder with a binder mixed. However, the core member 14 may be formed of a steel plate laminate formed by laminating a plurality of electromagnetic steel plates punched into a substantially U shape and integrally connecting them by caulking or the like.

The first and

second leg portions

16 and 18 of the core member 14 have

rectangular end surfaces

16a and 18a, respectively. These

end surfaces

16a and 18a serve as opposing surfaces of the core members when the two core members 14 are abutted in a substantially annular shape through the gap portion.

FIG. 2 is a perspective view showing a state in which a primary insert molding resin portion 22 made of a thermoplastic resin is formed on the core member 14 of FIG. The entire outer peripheral surface of the core member 14 excluding the

leg end surfaces

16 a and 18 a is covered with a primary insert molding resin portion 22. The primary insert molding resin portion 22 is formed by mounting the core member 14 in a molding die and injection molding a thermoplastic resin.

The primary insert molding resin part 22 includes a leg covering part 24 that covers the four sides of the

leg parts

16 and 18. The leg covering portion 24 has a function of securing an insulation distance between the coil and the reactor core when the coil is disposed around the

leg portions

16 and 18 as will be described later.

Moreover, the primary insert molding resin part 22 includes a wall part 26 protruding from the upper and lower surfaces. The wall portion 26 has a function of positioning the coil by abutting or substantially abutting against the coil end surface when the coil is disposed around the

leg portions

16 and 18.

Further, in the primary insert molding resin portion 22, the leg covering portion 24 of the first leg portion 16 is formed with an edge portion forming a rectangular frame shape protruding from the end surface 16a of the first leg portion 16, and the protruding portion thereof. In FIG. 2, recesses 25 a that are recessed in a substantially trapezoidal shape are formed on two sides facing each other in the lateral direction. On the other hand, the leg covering portion 24 of the second leg portion 18 is formed such that the edge portion forming a rectangular frame is substantially flush with the end surface 18a of the second leg portion 18 and is opposed to the lateral direction 2. Convex portions 25b projecting in a substantially trapezoidal shape are formed on the side portions.

The primary insert molding resin portion 22 as described above is similarly formed on the two core members 14 constituting the reactor core 12. Then, as shown in FIG. 2, the orientation of one core member 14 is reversed and the two core members 14 are arranged so that the first leg portion 16 and the second leg portion 18 face each other. Thereby, when the two core members 14 are connected in a ring shape, the concave portion 25a formed in the leg portion covering portion 24 of the first leg portion 16 and the convex portion formed in the leg portion covering portion 24 of the second leg portion 18. By fitting the portion 25b, the distance between the end surfaces 16a, 18a of the first and

second leg portions

16, 18 facing each other, that is, the dimension of the gap portion can be accurately defined.

As for the primary insert molding resin portion 22, the above-described concave and convex portions are also formed on the two sides facing in the vertical direction in the leg covering portion 24 formed in a rectangular frame shape around the leg end faces 16a and 18a. Each may be formed. In this way, the relative position in the horizontal direction when the two core members 14 are combined can be reliably positioned. Moreover, the said recessed part and a convex part have only the vertical and / or horizontal positioning function of the leg parts which oppose, and an opposing direction is because end surfaces other than the recessed part and convex part in a leg part coating | cover part contact | abut. The position may be determined to define the dimension of the gap portion.

Further, since the primary insert molding resin portion 22 is formed so as to cover the entire outer peripheral surface except for the leg end surfaces 16a and 18a, the core member 14 made of a dust core having a relatively low strength and easily chipped is prevented. In addition to having a protective function, as described later, it also has a function of ensuring insulation performance between the core member 14 and the metal case when the reactor is attached to the metal case.

FIG. 3 is an exploded perspective view showing a state in which the two core members 14, the coil 28, and the two gap plates 30 shown in FIG. 2 are assembled.

The coil 28 that constitutes the reactor 10 of the present embodiment is an edgewise coil that is formed in advance by winding a flat rectangular conductor wire that has been subjected to an insulating film treatment with, for example, enamel, around a coil, and two coils that are connected in series It is comprised by the

parts

28a and 28b. Each

coil part

28a, 28b is formed by winding a single continuous flat rectangular conductive wire.

Specifically, when the conducting wire end 29a of one coil portion 28a is started to be wound, a flat rectangular conducting wire is wound counterclockwise therefrom to form the coil portion 28a, from which the other coil portion is formed. The coil portion 28b is formed while moving to 28b and wound clockwise, and is connected to the winding end portion 29b. Thus, the conducting

wire end portions

29a and 29b protruding from the

coil portions

28a and 28b are connected to the power input / output terminal for the coil 28 (that is, the reactor 10).

The

coil portions

28a, 28b are formed in a substantially rectangular inner peripheral shape that is slightly larger than the leg covering portion 24 formed on the outer periphery of the

leg portions

16, 18 of the core member 14. Thereby, the

leg portions

16 and 18 of the core member 14 can be inserted into the

coil portions

28a and 28b. Further, the length in the winding direction of the

coil portions

28a, 28b is formed slightly shorter than the distance between the wall portions 26 of the primary insert molding resin portions 22 of the two core members 14 connected in an annular shape. Thus, when the reactor core 12 is assembled, the

coil portions

28a, 28b are positioned with a slight margin between the two wall portions 26.

The gap plate 30 is a rectangular flat plate member made of a nonmagnetic material, and for example, a ceramic plate such as alumina is preferably used. When the reactor is assembled, an adhesive 32 is applied to both sides of the gap plate 30 as shown in FIG. Thus, when the

leg portions

16 and 18 are inserted into the

coil portions

28a and 28b, respectively, and the two core members 14 are assembled in an annular shape, the gap plate is interposed between the end surfaces 16a and 18a of the first leg portion 16 and the second leg portion 18. The two core members 14 are bonded and fixed in a state where 30 is sandwiched. Therefore, in the reactor of this embodiment, the gap part formed between the two core members 14 is constituted by the gap plate 30 and the adhesive layer.

As the adhesive, a thermosetting adhesive such as an epoxy resin having strong adhesive force and excellent heat resistance is preferably used. Even when such a thermosetting adhesive is used, it can be sufficiently cured using the heat of the molten resin forming the secondary insert molding resin portion as will be described later, and the adhesive strength can be secured quickly. be able to.

However, the adhesive is not limited to the thermosetting type, and for example, a room temperature curing type adhesive may be used. Further, the adhesive may be applied in advance to the leg end surfaces 16 a and 18 a of the core member 14 instead of the gap plate 30. Further, when the two core members 14 each having the primary insert molding resin portion 22 are connected, the gap dimension between the end surfaces 16a and 18a of the first and

second leg portions

16 and 18 facing each other is convex with the concave portion 25a. Since it is precisely defined by fitting with the portion 25b, the gap plate may be eliminated and the gap portion may be configured with only a predetermined amount of adhesive. In this way, there are advantages that the number of parts and the cost can be reduced and the assembly can be facilitated.

FIG. 4 is a perspective view showing the reactor core 12 and the coil 28 in a state where the core member 14, the coil 28, and the gap plate 30 shown in FIG. 3 are assembled. As described above, when the

leg portions

16 and 18 are respectively inserted into the

coil portions

28a and 28b and the two core members 14 are connected via the gap plate 30 and the adhesive layer, the two core members 14 are interposed via the gap portions. Reactor cores 12 connected in an annular shape and coils 28 arranged around

leg portions

16 and 18 including gap portions in the reactor core 12 are assembled.

At this time, a slight gap is formed between the wall portion 26 of the primary insert molding resin portion 22 of the core member 14 and the end portions of the

coil portions

28a and 28b. Thereby, the molten resin forming the secondary insert molding resin portion described later can flow into the

coil portions

28a, 28b.

FIG. 5 is a perspective view showing a state where the secondary insert molding resin portion 34 is formed on the reactor core 12 and the coil 28 shown in FIG. In FIG. 5 (the same applies to FIG. 7), the

conductor end portions

29a and 29b extending from the secondary insert molding resin portion 34 are not shown. FIG. 6 is a perspective view showing a coil exposed portion 36 formed in the lower portion of the secondary insert molding resin portion 34.

The secondary insert molding resin portion 34 is formed by mounting the reactor core 12 and the coil 28 assembled as shown in FIG. 4 in another mold and injection molding a thermoplastic resin. The secondary insert molding resin portion 34 may be formed of the same thermoplastic resin material as the primary insert molding resin portion 22 or may be formed of a different thermoplastic resin material. Further, the secondary insert molding resin portion 34 is formed so as to cover substantially the entire periphery of the

coil portions

28 a and 28 b constituting the coil 28. Thereby, the two

coil portions

28a and 28b constituting the coil 28 are firmly fixed to the annular reactor core 12. In addition, since the secondary insert molding resin portion 34 is formed so as to cover the outside of the wall portion 26 of the primary insert molding resin portion 22, the two core members 14 are connected in an annular shape by the anchor effect of the wall portion 26. It is securely fixed in the state. In this way, the manufacture of the reactor 10 is completed.

The secondary insert molding resin portion 34 is formed so as to cover the upper portions of the

coil portions

28 a and 28 b, the outer peripheral side portion, and the inner peripheral side portion, thereby forming the two coil portions 28 a constituting the coil 28. , 28b are fixed to the reactor core 12. On the other hand, as shown in FIG. 6, the secondary insert molding resin portion 34 includes a coil exposed portion 36 that is exposed without the lower portions of the

coil portions

28 a and 28 b being covered. Thus, by providing the coil exposure part 36 in the secondary insert molding resin part 34, the heat dissipation from the

coil parts

28a and 28b can be made favorable.

As shown in FIGS. 5 and 6, the secondary insert molding resin portion 34 is integrally formed with a plurality of attachment portions 38 for attaching the reactor 10 to the reactor installation member by bolt fastening. In the present embodiment, an example in which four attachment portions 38 are formed is shown. A bolt insertion hole 40 is formed through the mounting portion 38. Thus, by integrally forming the attachment portion 38 on the secondary insert molding resin portion 34, it is not necessary to provide a special attachment portion made of a metal plate, and the number of components and cost can be reduced. In addition, although this embodiment demonstrated the example which integrally formed the attachment part 38 in the secondary insert molding resin part 34, it is not limited to this, The primary insert which is not covered with the secondary insert molding resin part 34 The attachment portion may be integrally formed with the exposed portion of the molded resin portion 22.

FIG. 7 is an exploded perspective view showing a state in which the reactor 10 to which the coil 28 is fixed by the secondary insert molding resin portion 34 is bolted onto the reactor installation member 44 through the heat dissipating material 42. FIG. 8 is a longitudinal sectional view of the reactor 10 fixed on the reactor installation member 44.

The reactor 10 manufactured as described above is inserted into the mounting portion 38 of the secondary insert molding resin portion 34 with bolts 46, and a reactor installation member, specifically, a bottom plate 44 of a metal case made of, for example, an aluminum alloy or the like. The sheet-like heat dissipation material 42 is sandwiched between the metal case bottom plate 44 and the metal case bottom plate 44 so as to be fixed.

On the bottom plate 44 of the metal case, there are formed mounting

recesses

50a and 50b in which the exposed portions of the

coil portions

28a and 28b protruding from the coil exposed portion 36 provided in the secondary insert molding resin portion 34 of the reactor 10 are fitted. Has been. As a result, as shown in FIG. 8, the lower portions of the

coil portions

28 a and 28 b exposed without being covered by the secondary insert molding resin portion in the reactor 10 may be in close contact with the metal case bottom plate 44 through the heat dissipation material 42. As a result, good heat dissipation from the

coil portions

28a, 28b to the metal case bottom plate 44 can be ensured. Moreover, since the heat dissipation material 42 is also an insulating sheet, it is possible to ensure insulation performance between the

coil portions

28a and 28b and the metal case bottom plate 44. In this embodiment, a sheet-like heat dissipation material is preferably used for reasons such as easy handling, but is not limited to this. For example, a thermally conductive and insulating adhesive is placed in the mounting recess. The adhesive layer may be applied in advance and used as a heat dissipation material.

Although not shown, the metal case bottom plate 44 constitutes a side wall of the cooler to which the cooling water is circulated or supplied, or a cooler on the back surface thereof (that is, the surface opposite to the mounting surface of the reactor 10). Are forcedly cooled by being provided adjacent to each other.

Subsequently, the manufacturing method of the reactor 10 having the above configuration is summarized as follows.

First, two core members 14, a coil 28 including

coil portions

28a and 28b, and two gap plates 30 are prepared (see FIGS. 1 and 3).

Subsequently, for the core member 14, a primary insert molding resin portion 22 made of a thermoplastic resin is formed so as to cover at least the outer peripheral surface excluding the facing surfaces of the core members (see FIG. 2).

Next, the two core members 14 are arranged so that the

leg portions

16 and 18 face each other, the

leg portions

16 and 18 are inserted into the

coil portions

28a and 28b, and the end surfaces 16a and 18a of the

leg portions

16 and 18 are connected to each other. The adhesive plate 32 is bonded and fixed through the gap plate 30 (see FIGS. 3 and 4).

Then, a secondary insert molding resin portion 34 made of a thermoplastic resin is formed on the reactor core 12 in which the coil 28 is disposed around the gap portion, and the

coil portions

28a and 28b constituting the coil 28 are connected to the reactor core. 12 (see FIG. 5). Thereby, manufacture of reactor 10 is completed.

As described above, in the reactor 10 according to the present embodiment, the

coil portions

28a and 28b disposed around the gap plate 30 and the primary insert molding resin portion 22 in the reactor core 12 are the secondary insert molding resin portions made of thermoplastic resin. 34, the potting step of the thermosetting resin in the vacuum furnace and the heat curing treatment in the heating furnace are eliminated, and a high cycle (for example, an insert molding time required for one reactor is about 40 seconds). ) Makes it possible to manufacture the reactor 10.

Moreover, in the reactor 10 of this embodiment, the insulation distance between the coil 28 and the core member 14 is ensured by the primary insert molding resin part 22 which covers the circumference | surroundings of the

leg parts

16 and 18 of the core member 14 to which the coil 28 is attached. The Accordingly, it is not necessary to assemble the coil around the insulating resin bobbin, and the resin bobbin can be omitted.

Further, a coil exposed portion 36 is provided in the secondary insert molding resin portion 34, and the exposed coil 28 is brought into close contact with the metal case bottom plate 44 with a highly heat conductive and insulating heat dissipation material 42 interposed therebetween. With the configuration in which 10 is attached, good heat dissipation and insulation can be secured for the coil 28.

Next, a modification of the above embodiment will be described with reference to FIGS. FIG. 9 is a perspective view similar to FIG. 6, showing a state where the secondary insert molding resin portion 34 protrudes from the coil exposed portion 36 and a burr portion 35 is formed.

Since the lower portions of the

coil portions

28a and 28b exposed in the coil exposed portion 36 have curved outer surfaces, the thermoplastic resin flows in when forming the secondary insert molding resin portion 34, and the

coil portions

28a and 28b are exposed. A burr portion 35 that partially covers the surface may be formed.

Even if the exposed portions of the

coil portions

28a and 28b are partially covered by the burrs 35, secondary insert molding is performed in order to improve heat dissipation to the metal case bottom plate 44 via the heat dissipation material 42. The resin portion 34 may be formed using a thermoplastic resin material having a higher thermal conductivity than the primary insert molding resin portion 22. In this case, for example, high thermal conductivity particles such as silica may be mixed with the same thermoplastic resin material as the primary insert molding resin portion 22 to improve thermal conductivity. Thus, if only the secondary insert molding resin portion 34 is formed of a high thermal conductivity thermoplastic resin material, an increase in material cost can be suppressed.

Further, when the secondary insert molding resin portion 34 is formed of a high thermal conductivity thermoplastic resin material as described above, the lower portions of the

coil portions

28a and 28b are provided without providing the coil exposed portions as in the reactor of the above embodiment. May be covered with the secondary insert molding resin portion 34. In this case, the presence of the secondary insert molding resin portion 34 between the

coil portions

28a, 28b and the metal case bottom plate 44 can improve the insulation performance. In this case, the heat dissipating material 42 may be slightly insulative as long as it has high thermal conductivity, and accordingly, the cost of the heat dissipating material can be reduced.

Further, when the secondary insert molding resin portion 34 is formed so as to cover the lower portions of the

coil portions

28a and 28b as described above, it may be mounted directly on the metal case bottom plate 44 as shown in FIG. Good. In this way, the cost can be reduced and the assembly can be facilitated by omitting the heat dissipation material, and the heat dissipation from the coil 28 to the metal case bottom plate 44 can be further improved.

In addition, although embodiment of this invention and its modification were demonstrated in the above, the reactor of this invention is not limited to the said structure, A various change and improvement are possible.

For example, in the above description, the primary insert molding resin portion 22 has been described as being formed so as to cover the entire outer periphery of the core member 14 except the leg end surfaces 16a and 18a. However, the primary insert molding resin portion 22 is not limited to this. Thus, only the portions corresponding to the leg covering portion 24 and the wall portion 26 may be formed to expose the whole or a part of the connecting portion 20 of the core member 14. By exposing the core member in this way, there is an advantage that heat dissipation from the core member is improved.

Further, in the above, the coil exposed portion 36 is provided at the lower portion of the secondary insert molding resin portion 34 to expose the lower portions of the

coil portions

28a and 28b, but when the reactor is attached to the lower surface of the metal case bottom plate 44, What is necessary is just to attach the reactor 10 shown in FIG. 5 in the direction turned upside down (namely, direction shown in FIG. 6).

Further, in the above-described embodiment, the example in which the reactor core 12 is configured by the two U-shaped core members 14 has been described. However, the present invention is not limited to this, and one is provided between the two U-shaped core members. Alternatively, the reactor core may be configured by interposing a plurality of rectangular parallelepiped core members. In this case, the reactor core includes three or more gap portions. And in this case, after forming the primary insert molding resin part similar to the said leg part coating | coated part 24 in the outer peripheral surface except the opposing surface of the core members of a rectangular parallelepiped core member, and connecting all the core members cyclically | annularly A secondary insert molding resin portion may be formed to fix the coil to the reactor core.

10 reactors, 12 reactor cores, 14 core members, 16 first leg, 18 second leg, 16a, 18a leg end face, 20 connecting part, 22 primary insert molding resin part, 24 leg covering part, 25a concave part, 25b convex part, 26 wall part, 28 coil, 28a, 28b coil part, 29a, 29b conducting wire end part, 30 gap plate, 32 adhesive, 34 secondary insert molding resin part, 35 burr part, 36 coil exposed part, 38 Mounting part, 40 bolt insertion hole, 42 heat dissipation material, 44 reactor installation member or metal case bottom plate, 46 bolt, 48 female screw hole, 50a, 50b mounting recess.

Claims

A reactor core formed by annularly connecting a plurality of core members via a gap portion;
A primary insert molding resin portion made of a thermoplastic resin provided to cover the outer peripheral surface of the reactor core except at least the facing surfaces of the core members;
A coil disposed around the gap portion and the primary insert molding resin portion of the reactor core;
A secondary insert molding resin portion made of a thermoplastic resin that is fixed to the reactor core by insert molding around the coil;
Reactor with
The reactor according to claim 1,
The secondary insert molding resin portion includes a coil exposure portion that exposes the coil at a portion facing the reactor installation member on which the reactor is installed, and the coil exposure portion contacts the reactor installation member via a heat dissipation material. A reactor characterized by
In the reactor according to claim 1 or 2,
The secondary insert molding resin part is formed of a resin material having higher thermal conductivity than the primary insert molding resin part.
In the reactor according to any one of claims 1 to 3,
The primary insert molding resin portion or the secondary insert molding resin portion is integrally formed with an attachment portion for bolting the reactor to a reactor installation member.
A reactor manufacturing method comprising: a reactor core in which a plurality of core members are annularly connected via a gap portion; and a coil provided around the reactor core including the gap portion,
Preparing the plurality of core members and the coil;
Covering at least the outer peripheral surface of the core member excluding the facing surfaces of the core members to form a primary insert molding resin portion made of a thermoplastic resin,
In a state where the plurality of core members are inserted through the coil, it is connected annularly through a gap portion,
A reactor in which a secondary insert molding resin portion made of a thermoplastic resin is formed around the coil disposed around the gap portion and the primary insert molding resin portion of the reactor core, and the coil is fixed to the reactor core. Manufacturing method.
In the manufacturing method of the reactor according to claim 5,
When forming the secondary insert molding resin portion, a coil exposed portion that exposes the coil is formed at a portion facing a reactor installation member on which the reactor is installed, and the coil exposed portion is disposed via the heat dissipation material. A reactor manufacturing method, wherein the reactor is assembled in contact with a reactor installation member.
In the manufacturing method of the reactor of Claim 5 or 6,
The method for manufacturing a reactor, wherein the secondary insert molding resin portion is formed of a resin material having higher thermal conductivity than the primary insert molding resin portion.
In the manufacturing method of the reactor as described in any one of Claim 5 to 7,
A method of manufacturing a reactor, wherein when forming the primary insert molding resin portion or the secondary insert molding resin portion, an attachment portion for bolting the reactor to a reactor installation member is integrally formed.